Flashlight



y 1960 D. c. MUNRO 2,937,266

FLASHLIGHT Filed Sept. 6, 1957 i r r INVENTOR Wm/J 64% United States Patent 2,937,266 FLASHLIGHI David C. Munro, Chicago, Ill. Application September 6, 1957, Serial No. 682,520

5 Claims. c1. 240-10.

My invention relates to a flashlight, and more particularly, to a flashlight of the pen-light type, that is adapted to be clipped, for instance, to the pocket of ones shirt or coat. 7

Conventional penlights and other kinds of flashlights that are held in the hand are expensive to manufacture and frequently are troublesome to operate. The reason for this is that most of the parts, such as the casing and the switch elements, are formed from expensive metals, and the switch is relatively complicated, its elements are in themain hidden from the user, and it depends on some mechanical linkage to complete the circuit required to light the flashlight.

In efforts to reduce manufacturing costs, one course of action has been to reduce the size of the flashlight,

which results in a less effective beam of light being provided, and presents difficulties in switch design. However, so far as I am aware, the industry has continued to employ the conventional complicated and hidden switch designs that inherently maintain manufacturing costs while at the same time are highly susceptible to corrosion and the like which cannot be detected by the flashlight owner, andwhich inevitably lead to malfunctioning of the flashlight. I Y a A principal object of my invention is to provide a simplified flashlight that permits a marked reduction in manufacturing costand yet provides a beam of light that is comparable to that of larger conventional flashlights. 1 Another principal object of my invention is to provide an improved switch arrangement that exposes the princip'al elements thereof to the user, and materially simplifies the design of switches for flashlights in general.

A further object of the invention is to improve on and simplify the design of flashlights in general.

Other objects, uses, and advantages will be obvious or become apparent from a consideration of the following detailed description and the application drawings.

light of Figs. 1 and 2; and

I Fig. 5 is a perspective view of the modified form of casing for the flashlight.

Reference numeral 10 of Fig's. i.l and 2, indicates a preferred embodiment of the invention vwhich includes a tube or casing '12 that carries one'or more batteries 14 and electric light bulb 16, top end cap" 18 a'nd'bottorn end cap 20 for casing 12, resilient clip and. switch member 22, and

securing ring 24.

' The casing 12 in the'illustrated embodiment is formed from three ply kraft dielectric paper formed in any suitable manner tothe rounded shape (in the illustrated embodiment) indicated in Fig. 3. The kraft paper forms a relatively rigid but deformable inner layer 26 on the outer surface ofwhich is secured a layer of metal foil 28. The foil should have good electrical conductance properties and should extend from the bottom end of the easing into contact with the member 22, though it need not entirely surround the casing. The foil material may be, for instance, the conventional paper-backed aluminum foil that is readily available on the market, the paper backing being on the inner side of the foil layer. Alternately, the casing 12 may be formed from a plastic material metallized to provide the electrical circuiting required.

The battery or batteries 14 may comprise any conventional type and ordinarily include a metallic casing 30 formed with the conventional upper terminal 32. The casing 30 forms the other terminal of the battery, contact with other batteries on the bottom of the flashlight usually being made at the bottom 33 of the battery. In the illustrated embodiment, the usual paper or cardboard wrapping is omitted in interests of economy.

The bulb 16 may comprise any conventional form of pen-light bulb that includes an element connected by appropriate leads to casing 42 (which is threaded in the illustrated embodiment, but need not be) and terminal 44, respectively. The bulb 16 ordinarily includes a transparent flashlight globular enclosure 46 including a bulbous end 48 that magnifies light rays passing outwardly of the bulb.

The-bulb 16 carries a deformable resilient centering ring 50, which is received on the screw threaded portion of the illustrated form of bulb 16. The ring 50, which may be formed from rubber or rubberlike materials, is

preferably proportioned so that it slidingly engages the interior surface of casing 12 and yet provides a centering action on the cylindrical portion 42 of the bulb. As indicated in Fig. 2, the centering ring 50 is preferably positioned so that it does not entirely overlie the portion 42 of the bulb, but includes a portion 52"that extends over the terminal 44 of the bulb. This gives the ring 50 a tapered configuration which facilitates the insertion of the bulb and ring within the casing from the front or top end of the flashlight.

Alternately, the ring 50 may take the form of fiber washer 50a shown in Fig. 4, or even similarly shaped metal washers may be employed.

The top cap 18 in the illustrated embodiment comprises an annular threaded portion 60 that is integrally united with a dished reflector portion 62 formed with a central perforation 64. The bottom cap 20 likewise includes an annular threaded portion 60, but also includes a disc-like portion 66 formed with an inwardly extending indentation 68 thatis adapted to abut against the bottom of the adjacent battery 14, as indicated in Fig. l.

Preferably caps 18 and 20 are formed from a relatively hard substance such as a metal or an appropriate plastic so that when threaded on the ends of casing 12, they form their own screw'threading in the casing. As the cap 18 is screwed into place, the end 48 of bulb 16 extends outwardly of the reflector portion 62 until the reflector portion 62 bears against the enlarged portion 70 of bulb enclosure 46. This provides a second centering action on the bulb 16. As the cap 20 is screwed into place on the casing 12, the indentation 68 is placed into electrical conductive engagement with the bottom of the adjacent battery 14. Of course, cap 20 should be formed from or include a material that conducts electricity, since it forms part of the electrical circuit of the flashlight.

The act of screwing caps 18 and 20 on casing 12 brings the bulb 16'and batteries 14 in electrical contact, which eliminates the need for the conventional spring between cap 20 and the lower battery. Where cap 20 is to be provided with a rounded end, however, a spring may be employed to establish the electrical circuit between the end battery and cap 20.

Theclip and switch member 22 comprises an elongated element formed, from spring steel, or the like, into the configuration generally illustrated in Fig. 2. It will thus be seen that the member 22 includes a relatively flat center portion 80 that separates two outwardly bent portions 82 and 84. The portion 82 includes end portion 86 having a generally V-shaped configuration, which, when the member 22 is applied to casing 12, positions leg 88 of end 86 at a relatively small angle with respect to casing 12 and leg 90 of end 86 at a relatively large angle with respect to casing 12. Leg 90 merges into an upwardly inclined portion 92 that in turn merges into a connecting portion 94 that is integrally united with central portion 80.

The portion 84 of the clip member 22 comprises an upwardly inclined segment 100 having a slight bend formed as indicated at 102; portion 84 is turned at approximately a right angle at 104 to provide a transver'sely extending contact arm 106. Ann 106 is aligned with a perforation 108 formed in the casing adjacent the cylindrical portion 42 of bulb 16.

The member 22 is retained on casing 12 by retaining ring 24, which is preferably so proportioned that it closely engages the outer surface of casing 12. The ring 24 is applied to casing 12 before cap 18 and with the portion 84 of the clip member held flat against the casing (end 106 of member 22 being previously inserted in perforation 108). When the ring is positioned as shown in Fig. 2, the portion 94 and bend 102 of the clip member bend to hold the clip member in the position shown with respect to the ring 24. Ring 24 holds portion 80 of clip member 22 against foil layer 28 of the casing to establish the electrical contact between these elements of the flashlight.

The casing 12 may be indented as at 110 and 112 where the clip member 22 contacts same to maintain the clip member in the position illustrated. In addition, portion 80 may be curved away from casing 12 at its center portion so that ring 24 urges portion 80 into closer contact with the casing at the ends of portion 80. This together with perforation 108 provides three effective points of support for the clip member, and enhances the electrical connection between the foil layer 28 and the clip member.

The ring 24 may be formed from any suitable material, but preferably is either light in color or luminous so that the flashlight may be easily located in the dark. It may be made from the same material forming layer 26 of casing 12, but in any event it should be semi-rigid and relatively strong.

The device 10 may be assembled by first placing the battery or batteries 14 in the casing 10 in the manner indicated in the drawings and applying the bottom cap to the casing. The bulb 16 is then applied to ring to dispose these parts in the relation indicated in Fig. 2. The tapered end or portion 52 of ring 50 is then inserted into the top end of the casing 12 and the bulb pushed into the casing until terminal 44 contacts the terminal 32 of the upper battery 30. The clip member 22 is then applied to the casing in the manner indicated in Fig. 2, with portion 106 thereof extending through perforation 108 that is formed in casing 12. The member 22 is followed by top cap 18, applied to casing 12 by turning same on the casing; cap 18 is preferably turned until the rim of perforation 64 bears against the cover 46 of the bulb, as described above.

The clip member 22 forms the switch of the flashlight, and completes the circuit between the foil layer 28 and the bulb 16.

thence from the foil layer through clip member 22 to the cylindrical portion 42 of bulb 16, the filament 40, the bulb terminal 44, and back to the battery 14.

Preferably, the clip member 22 is tensioned so that portion 84 normally assumes the position indicated in The electrical circuit is thus from the battery through the bottom cap 20 to the foil layer 28 and Fig. 2, and portion 82 bears against the casing 12 at its end 86. When one desires to turn the flashlight on, the portion 100 of the clip member 22 is pressed to bring the contact arm 106 into contact with the cylindrical portion 42 of bulb 16. If one desires to maintain the beam of light without pressing on the clip member 22, one merely slides the retaining ring 24 to the left of Fig. 2 to bring portion 100 of clip member 22 underneath ring 24; this holds the end 106 against the cylindrical portion 42 of bulb 16. The switch is released and the light turned off by merely forcing ring 24 to the right to position same as shown in Fig. 2, whereupon the inherent springiness of the material from which clip member 22 is formed moves arm 106 to the position shown in Fig. 2, thus breaking the electrical circuit.

The outwardly bent portion 82 of clip member 22 forms a clamping arm that permits the light 12 to be secured to ones shirt or coat pocket. The relatively small angle that leg 88 of end 86 makes with the casing facilitates the entry of the cloth that forms the pocket between the clip and the casing, while the relatively large angle that leg 90 of end 86 makes with casing 12 tends to preclude removal of the clip from ones pocket by bunching up the cloth material as the cloth starts to move outwardly of the clip member, and thus insures against accidental removal of the light from its desired position in ones pocket.

When arm 106 is pressed against bulb 16, bulb 16 is maintained in its position by ring 50 and cap 18, which insures that the bulb Will always be so held that the electrical circuit will be preserved. As the reflector remains in contact with the bulb, the proper relationship between the bulb and the reflector is maintained as long as the flashlight is in assembled relation. Furthermore, reflector portion 62 extends from the end of cap 18 all the way to and into contact with the bulb 16, which provides an extended light reflecting surface not found in conventional flashlights.

The foil is secured to the casing 12 by any suitable form of adhesive which is preferably of a waterproof type.

As described above, the batteries 14 may be of any standard type, but in accordance with the principles of my invention, the usual paper or cardboard wrapping of the battery may be omitted since the electrical circuit of the flashlight is on the outside of casing 12. This materially reduces the cost of producing batteries 14.

The outer surface 120 of reflector 62 may be coated with a highly reflective substance that will increase the amount of light reflected. The coating applied may be of chrome, tin or nickel plating in form.

The bend 102 in portion 84 of clip member 22, in addition to its centering action on ring 24, prevents the ring 24 from accidentally being forced over the portion of clip member 22 and thus accidentally turning the flashlight on. Preferably, the end 106 is positioned not quite at 90 degrees with respect to portion 100 so that its tip moves toward the bulb 16 as portion 100 is pressed toward casing 12.

Fig. 5 illustrates a modified form of casing or tube 12a which is formed entirely of metal and includes a reflector portion 62a that is given the same shape as reflector 62, but is made integral with the casing 12a. The bottom end of casing 12a is preferably screw-threaded to receive a cap 20, similar to cap 20, of Fig. 1. Casing 12a is formed with perforations 108 to receive an arm of a clip member 22. The identations 110 and 112 are omitted in this embodiment of the invention, but may be employed if so desired.

Alternately, cap 20 may be made integral with casing 12a and cap 18 employed in place of integral reflector portion 62a. I also contemplate that both caps may be omitted and the ends of the casing 12a machined to close the ends of the casing against the bulb and the batteries; a metal spinning operation would satisfactorily accomplish this, and, of course, the bulb and batteries would 'be permanently sealed within the casing.

The internal elements of a flashlight employing casing 12a are inserted from the bottom end of same in proper order. The battery or batteries employed would have to have the conventional wrapping, and centering ring 50 should be of the non-conductive type in this embodiment of the invention. Member 22 and ring 24 may be applied to casing 12a in the same manner as described above.

My invention has or provides a number of important advantages. For instance, my flashlight is obviously composed of less elements than are normally found in conventional flashlights. By employing a penlight bulb with a reflector, the beam of light that is thrown off is partied larly effective. Even though the batteries are not biased toward the bulb by the conventional spring arrangement, I am" able to provide an effective and positive electrical contactv between the bulband the battery. An effective and positive electrical contact is also provided at the switch, and it will be noted that the electrical contact made by the switch is not dependent upon the action of some spring member or members, or linkage of members, that are unseen by the user. By making the principal elements of my switch visible, it is apparent that all defects, if occurring, may be readily detected, and the simplified nature of the switch practically eliminates the occurrence of defects.

By employing the simplified construction illustrated, my flashlight is or may be much shorter and lighter than conventional lights. It is obvious that the construction is much simplified when compared to conventional flashlights, and this adapts the illustrated embodiments of the invention for premium item use, as for instance, when inserted in packages of cereal and the like. Also, the simplified form of construction adapts the flashlight for use as an educational device which will aid' youngsters in learning the principles of electricity and gaining dexterity in the use of their hands as well as in acquiring mechanical ability.

While the illustrated embodiments of the invention are found in cross-sectional configuration, obviously other configurations may be employed.

The foregoing description and the drawings are given merely to explain and illustrate my invention, and the invention is not to be limited thereto, except insofar as the appended claims are so limited since those skilled in the art who have my disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.

I claim:

1. An electric flashlight comprising a tube including an electrical current conductive portion forming at least part of the outer surface of said tube, an electric battery received in said tube, a bulb mounted in said tube at one end thereof and in electrical contact with one terminal of said battery, said electrical conductive por tion of said tube being in electrical contact with the other terminal of said battery, said bulb including a generally cylindrical portion forming one contact of the bulb, a base portion forming the other contact of the bulb and a transparent globular portion covering the illuminating element of the bulb, said other contact of said bulb being in electrical contact with said one terminal of said battery, a centering ring received about said cylindrical portion of said bulb, said ring being concentrically and complementarily arranged within said tube to center said bulb within said tube with said other contact of said bulb in electrical contact with said one terminal of said battery, an electrical current conductive spring member contacting said portion of said outer surface of said tube and extending longitudinally of said tube from said one end thereof toward the other end thereof, said member including a relatively flat portion extending parallel to said tube and separating two outwardly bent portions, one of said outwardly bent portions including an inwardly directed projection that extends transversely of said tube, said tube being formed with a perforation in alignment with said one contact of said bulb through which said projection extends to contact said one contact of said bulb, said projection of said spring member being biased away from said bulb, a clamping sleeve slidably received about said tube with said relatively flat portion of said spring member being received between said sleeve and said tube, said sleeve being proportioned to clamp said member'to said tube to hold said spring member in engagement with said tube, the other of said outwardly bent portions including an end portion that extends toward the other end of said tube and that resiliently bears against said tube when said member is received between said ring and said tube to form a clip for securing the flashlight to ones pocket or the like, and said one end of said tube including a cap member formed with a generally concave reflector portion facing outwardly of said tube and defining a central perforation through which said globular portion of said bulb extends from within said tube, with the portion of said reflector portion defining said central perforation contacting said globular portion of said bulb to efiect a centering action thereon, whereby said one bent portion of said spring member may be pressed to place said projection in electrical contact with said one contact of said bulb to light the flashlight, and said centering ring and said cap member maintain said bulb centrally disposed within said tube, said one outwardly bent portion of said spring member being inclined away from said tube at a relatively small angle, whereby said sleeve may be moved thereagainst to partially overlie said one bent portion of said spring member to hold said inwardly directed projection in contact with said one contact of said bulb.

2. The flashlight set forth in claim 1 wherein said tube is formed from a relatively rigid but deformable material, and wherein said other end of said tube is formed with a cap member, the last mentioned cap member being in electrical contact with said other terminal of said battery and said portion of said tube, said cap members comprising screw threaded elements that may be turned onto said tube to deform said tube whereby said cap members are afiixed to said tube.

3. The flashlight set forth in claim 1 wherein said tube is formed from a relatively rigid material, said cap member being integrally united with said tube, said tube including a second cap member at its other end, said second cap member being in electrical contact with said other terminal of said battery and said portion of said tube, and means for securing said second cap member to said tube.

4. The flashlight set forth in claim 1 wherein said centering ring is proportioned to be enlarged when received about said cylindrical portion of said bulb, said ring being only partially received on said cylindrical portion of said bulb whereby said ring is formed with a tapering end portion that facilitates insertion of said ring and said bulb within said tube.

5. The flashlight set forth in claim 1 wherein said flat portion of said spring member and said end portion of said other bent portion thereof are received in indentations formed in said tube.

References Cited in the file of this patent UNITED STATES PATENTS 1,111,546 Oelman Sept. 22, 1914 1,839,971 Korsen Jan. 5, 1932 1,937,651 Graubner Dec. 5, 1933 2,166,282 Benjafield July 18, 1939 2,293,660 Nicholas Aug. 18, 1942 FOREIGN PATENTS 647,966 Germany July 17, 1937 

